Types of Dimensioning and Weighing Technologies Used in DWS Systems: Part 1
For early adopters of warehouse automation solutions, dimensioning and weighing technologies have long enabled intelligent decision-making, underscoring a degree of awareness in the market. So, are automatic dimensioning and weighing machine setups still worth examining?
The answer is yes, and we will explore this question throughout this blog as we list, compare, and contrast different dimensioning and weighing systems. Let’s dive right in!
Quick Recap: What Is the Importance of DWS Solutions in Warehousing, Intralogistics, 3PL Operations, etc.?
It is already well-established for these technologically mature players that the dimensioners and scales used in DWS Systems for capturing parcel L x B x H and weight, i.e., DIM (dimensional weight), ensure:
- Optimised storage and retrieval process
- Minimal waste packaging (in operations where packing is done by the logistics partner/unit(s))
- Intralogistics G2P (Goods to Person) robots or automated vehicles (AGVs, AGCs) management based on the dimensions and load capacity of the carriers
- Outbound logistics planning
Most importantly, the input from the DWS solution is used to accurately and transparently bill customers, based on considerations such as operational costs for handling the parcel (partially), the impact of DIM on in-vehicle freight space, the load the parcel exerts, and profit margins. However, the market has evolved, making use cases must-haves rather than novelties.
What Should CTOs Venturing into Warehouse Automation Know About Dimensioning Weighing Solutions?
During the last 18 months, we have spoken with several key decision-makers from various warehousing and third-party logistics (3PL) operations, particularly those among the early adopters of warehouse automation solutions across India. In the early stages of warehouse automation trends in the market, pre-integrated DWS Solutions drastically transformed the dimensioning and weighing processes. However, our conversations with the stakeholders from different companies suggest a shift in expectation from Dimensioning, Weighing, and Scanning Systems and other solutions, revealing the answer to a question we have repeatedly explored: What do today’s users expect from automated dimensioning and weighing systems?
The key focus today is on the efficiency and accuracy of readings from intralogistics automation solutions rather than the use cases and functionality of the dimensioning and weighing systems. Hence, it is more important than ever to analyse the different technologies powering pallet and parcel dimensioning and weighing systems.
What Are the Different Weighing Scale Technologies for Logistics, 3PL Warehousing, E-Commerce Warehousing, etc.?
The following are the prevalent weighing scale technologies used in volumetric weight measurement systems:
- Strain Gauge Scales: One of the most high-capacity, heavy-duty scales used in industrial dimensioning and weighing systems, strain gauge scales are defined by two components:
- Load Cells, i.e., sensors under the scale platforms, which convert the pressure applied by the objects placed into electrical energy.
- A Strain Gauge, which acts as a resistor in which mechanical compression causes a change in electrical resistance
When this change in electrical resistance is converted into a voltage difference by Wheatstone bridge circuits, the output is amplified via an amplifier, which in turn sends signals to an Analog-to-Digital Converter (ADC). Finally, ADC, designed to transform the voltage readings into weight, displays the shipment weight.
In the case of moving shipments, as is the case for parcels on Dynamic DWS Systems, solution-builders integrate high-sensitivity, high-speed load cells and other electronics used in the scale.
- EMRF Scales: EMRF scales stand for electromagnetic force restoration scales with a typical fulcrum and lever mechanism found in seesaws (first-class levers). However, here, counterweights are not used to balance the load exerted by the object in question. Instead, a magnetic field acts on the other side of the lever until it reaches equilibrium, that is, the balancing position. The current needed to balance the load is then converted, leveraging a microprocessor, into the weight of the object.
- SAW Scales: Surface Acoustic Wave (SAW) scales use springs made of piezoelectric materials, with electrodes (transmitters and receivers). When the spring compresses, thanks to the material’s property, waves are created within the material. The electrodes in scale convert these mechanical waves into electrical signals, which in turn are used to back-track the load exerted by the shipment.
However, which of these volumetric weight measurement systems are suitable for intralogistics in warehouses, docks, and manufacturing units, where integrated dimensional weighing systems or DWS Systems are installed? Let’s discover that in the following sections!
What Should Be the Key Considerations for Selecting Weighing Scale Technologies?
Operations managers should be aware of the following pointers before investing in weighing scale technologies for logistics, warehousing, e-commerce hubs, etc.:
- Cost of acquisition
- Scalability
- Degree of accuracy
- Recalibration or maintenance frequency
- Load capacity, i.e., diversity and suitability of applications
Which Weighing Scale Technology Is Ideal for Logistics, Warehousing, and Other Heavy-duty Operations?
Below is a table of comparison featuring strain gauge scales, EMRF scales, and SAW scales:
Technology | Accuracy | Load Capacity | Cost of Acquisition | Maintenance |
Strain Gauge | Sufficient | Highest | Within Average Digital Transformation Budgets | Infrequent |
EMRF | High | Small loads | Exorbitant | Extensive |
SAW | Very High | High | Relatively Higher than Strain Gauge | Infrequent |
Here are some takeaways from the table:
- Accuracy & Load Capacity: While extremely accurate, EMRF scales are typically used in labs. The weighing scale technology, at least in its usual configurations, proves to be accurate only for small measuring quantities. SAW scales, on the other hand, have a larger load capacity and are ultra-sensitive to the load exerted by shipments. However, the weight threshold of SAW scales still may not suffice for a section of the shipments handled by warehouses.
This is where strain gauge scales, with their high load capacity and moderate accuracy—ideal ranges for weighing scales for logistics—-save the day!
- Cost of Acquisition: Strain gauge scales are relatively cheaper than the other two industrial weight technologies.
Additionally, despite the load capacity limitations, in terms of maintenance needs, SAW scales thrive in industrial settings due to their ruggedness and high accuracy. Hence, for high-stakes operations with moderate load capacity needs, a DWS System with SAW scale is perfect. Such scenarios include sensitive chemical measurements at an industrial level, measuring individual machinery parts for mission-critical devices, etc. So, unless the warehouses’ SLA involves quality control, or if the organisations’ or the industry’s SOP demands high precision, SAW scales may not be suitable for warehouses. Moreover, for big pallets as well, SAW scales could be unsuitable. Therefore, for the maximum range of load handling, critical for the different weight categories found in warehouses, strain gauge scales are a must-have.
What Are Some Additional Considerations Before Selecting Strain Gauge Weighing Scale Technology for Logistics, Warehousing, etc.?
Here are some limitations of strain gauge scales:
- Temperature fluctuations can impact readings, and hence, it is important to control the warehouse temperature if the ambient temperature is likely to exceed or dip below a certain range. However, in most warehouses, a drastic temperature change is rare.
- Adhesion between the scale platform and load cells may wear off, causing “non-reads” or poor readings.
- Users must factor in the built-in error range due to energy loss in the mechanical and electrical process.
- Springs do not always return to the same position, leading to errors, thereby making maintenance cycles vital.
- It is important to check for adherence to international metrological and quality standards, which are the OIML R 51 standards of the International Organization of Legal Metrology (OIML). These compliance standards are for dynamic and automatic weighing processes. Similarly, the ISO/IEC 17025 calibration and measurement accuracy standards are vital.
What are the Different Configurations of Strain Gauge Weighing Scales?
Some of the best-known strain gauge configurations include:
- Integrated Forklift and Pallet Scales
- Static Floor Scales
- Bench Scales
- In-Motion Conveyor Scales
What Are the Weighing Scale Technologies for Logistics, Warehousing, etc., Used by Quinta?
As a Full-stack Warehouse Automation, Intralogistics Automation, and Manufacturing Automation system, Quinta has a long-standing experience in building strain gauge volumetric weight measuring systems, both for Static DWS solutions and Dynamic DWS solutions. We have built these DWS Solutions to elevate the efficiency level of operations across different industries, particularly for warehousing units.
Additionally, our team of hardware experts have extensive domain knowledge, including that of EMRF scales and SAW scales, as well as automated manufacturing workflows for sectors that demand optimal accuracy, such as Cold Chain operations, chemical plants, pharmaceutical companies etc. Therefore, we are proud to say that our expertise sets us apart from other solution-builders in the market, enabling us to plan, execute, and integrate different weighing scales technologies in various workflows, involving and excluding DWS Systems.
Similarly, our software team boasts a track record of integrating a wide range of hardware to different software platforms, in addition to our WMS and MES software.
Curious to know more? Our next blog explores the variety of dimensioning technologies in the market and the ones we would recommend for seamless warehouse automation!
To hit the ground running with our automation setups, contact us now, and one of our executives will be in touch with you as soon as possible!
Frequently Asked Question
Quinta offers a high-precision setup that best serves the warehouses’ and manufacturing units’ SLAs, the business goals of the industry player, and the budget allocated for the Digital Transformation project. The unique factor of collaborating with Quinta is our wealth of experience and dedicated team of domain experts, along with a complementary automation opportunity consultation, which is designed to help you evaluate the merit of your infrastructure in terms of overall efficiency, projections, resilience against or readiness for trends, and competitiveness.
A big chunk of Quinta’s automation solution-building projects is with different warehousing operations attached to industries such as 3PL, e-commerce (in-house warehouse), etc. Hence, given the price advantage of the volumetric weighing solution, its in-range accuracy, and robust load capacity, which prove to be the ideal combination of configurations for a warehouse DWS System weighing scale, we integrate this scale in several projects.
Yes, our capabilities cover different industrial dimensioning and weighing systems, warehouse automation solutions for varying workflows, and the weighing scale technologies for logistics, warehousing, etc.
